US9202976B2 - Group III nitride semiconductor light-emitting device and method for producing the same - Google Patents
Group III nitride semiconductor light-emitting device and method for producing the same Download PDFInfo
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- US9202976B2 US9202976B2 US14/197,057 US201414197057A US9202976B2 US 9202976 B2 US9202976 B2 US 9202976B2 US 201414197057 A US201414197057 A US 201414197057A US 9202976 B2 US9202976 B2 US 9202976B2
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- 239000004065 semiconductor Substances 0.000 title claims abstract description 238
- 150000004767 nitrides Chemical class 0.000 title claims abstract description 51
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 43
- 239000000758 substrate Substances 0.000 claims abstract description 124
- 229910052594 sapphire Inorganic materials 0.000 claims abstract description 109
- 239000010980 sapphire Substances 0.000 claims abstract description 109
- 239000007789 gas Substances 0.000 claims abstract description 70
- 239000002994 raw material Substances 0.000 claims abstract description 56
- 229910021478 group 5 element Inorganic materials 0.000 claims abstract description 20
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 claims description 22
- 238000000034 method Methods 0.000 claims description 10
- 229910021529 ammonia Inorganic materials 0.000 claims description 8
- XCZXGTMEAKBVPV-UHFFFAOYSA-N trimethylgallium Chemical compound C[Ga](C)C XCZXGTMEAKBVPV-UHFFFAOYSA-N 0.000 claims description 7
- 230000000737 periodic effect Effects 0.000 claims 3
- 230000001737 promoting effect Effects 0.000 claims 2
- 230000015572 biosynthetic process Effects 0.000 abstract description 31
- 238000000605 extraction Methods 0.000 description 8
- 239000013078 crystal Substances 0.000 description 6
- 230000008569 process Effects 0.000 description 6
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 5
- 230000000052 comparative effect Effects 0.000 description 4
- 230000004048 modification Effects 0.000 description 4
- 238000012986 modification Methods 0.000 description 4
- 238000005229 chemical vapour deposition Methods 0.000 description 3
- 230000003247 decreasing effect Effects 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 238000002474 experimental method Methods 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- JLTRXTDYQLMHGR-UHFFFAOYSA-N trimethylaluminium Chemical compound C[Al](C)C JLTRXTDYQLMHGR-UHFFFAOYSA-N 0.000 description 3
- BLRPTPMANUNPDV-UHFFFAOYSA-N Silane Chemical compound [SiH4] BLRPTPMANUNPDV-UHFFFAOYSA-N 0.000 description 2
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 2
- 230000005540 biological transmission Effects 0.000 description 2
- 239000012159 carrier gas Substances 0.000 description 2
- 239000002019 doping agent Substances 0.000 description 2
- 239000001257 hydrogen Substances 0.000 description 2
- 229910052739 hydrogen Inorganic materials 0.000 description 2
- 229910052757 nitrogen Inorganic materials 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- IBEFSUTVZWZJEL-UHFFFAOYSA-N trimethylindium Chemical compound C[In](C)C IBEFSUTVZWZJEL-UHFFFAOYSA-N 0.000 description 2
- 229910002704 AlGaN Inorganic materials 0.000 description 1
- MHYQBXJRURFKIN-UHFFFAOYSA-N C1(C=CC=C1)[Mg] Chemical compound C1(C=CC=C1)[Mg] MHYQBXJRURFKIN-UHFFFAOYSA-N 0.000 description 1
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 238000005253 cladding Methods 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 238000002425 crystallisation Methods 0.000 description 1
- 230000008025 crystallization Effects 0.000 description 1
- 238000001312 dry etching Methods 0.000 description 1
- 239000007772 electrode material Substances 0.000 description 1
- 238000005530 etching Methods 0.000 description 1
- 238000002248 hydride vapour-phase epitaxy Methods 0.000 description 1
- 150000002431 hydrogen Chemical class 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 230000005012 migration Effects 0.000 description 1
- 238000013508 migration Methods 0.000 description 1
- 238000005121 nitriding Methods 0.000 description 1
- 125000004433 nitrogen atom Chemical group N* 0.000 description 1
- 229910000069 nitrogen hydride Inorganic materials 0.000 description 1
- 230000005855 radiation Effects 0.000 description 1
- 230000006798 recombination Effects 0.000 description 1
- 238000005215 recombination Methods 0.000 description 1
- 229910000077 silane Inorganic materials 0.000 description 1
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L33/00—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L33/02—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor bodies
- H01L33/20—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor bodies with a particular shape, e.g. curved or truncated substrate
- H01L33/22—Roughened surfaces, e.g. at the interface between epitaxial layers
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
- H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
- H01L21/02104—Forming layers
- H01L21/02365—Forming inorganic semiconducting materials on a substrate
- H01L21/02367—Substrates
- H01L21/0237—Materials
- H01L21/0242—Crystalline insulating materials
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
- H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
- H01L21/02104—Forming layers
- H01L21/02365—Forming inorganic semiconducting materials on a substrate
- H01L21/02367—Substrates
- H01L21/02428—Structure
- H01L21/0243—Surface structure
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
- H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
- H01L21/02104—Forming layers
- H01L21/02365—Forming inorganic semiconducting materials on a substrate
- H01L21/02436—Intermediate layers between substrates and deposited layers
- H01L21/02439—Materials
- H01L21/02455—Group 13/15 materials
- H01L21/02458—Nitrides
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
- H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
- H01L21/02104—Forming layers
- H01L21/02365—Forming inorganic semiconducting materials on a substrate
- H01L21/02436—Intermediate layers between substrates and deposited layers
- H01L21/02494—Structure
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
- H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
- H01L21/02104—Forming layers
- H01L21/02365—Forming inorganic semiconducting materials on a substrate
- H01L21/02436—Intermediate layers between substrates and deposited layers
- H01L21/02494—Structure
- H01L21/02496—Layer structure
- H01L21/02502—Layer structure consisting of two layers
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- H—ELECTRICITY
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- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
- H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
- H01L21/02104—Forming layers
- H01L21/02365—Forming inorganic semiconducting materials on a substrate
- H01L21/02518—Deposited layers
- H01L21/02521—Materials
- H01L21/02538—Group 13/15 materials
- H01L21/0254—Nitrides
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- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
- H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
- H01L21/02104—Forming layers
- H01L21/02365—Forming inorganic semiconducting materials on a substrate
- H01L21/02612—Formation types
- H01L21/02617—Deposition types
- H01L21/0262—Reduction or decomposition of gaseous compounds, e.g. CVD
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- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L33/00—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L33/005—Processes
- H01L33/0062—Processes for devices with an active region comprising only III-V compounds
- H01L33/0066—Processes for devices with an active region comprising only III-V compounds with a substrate not being a III-V compound
- H01L33/007—Processes for devices with an active region comprising only III-V compounds with a substrate not being a III-V compound comprising nitride compounds
Definitions
- the present invention relates to a Group III nitride semiconductor light-emitting device and to a method for producing the same. More particularly, the present invention relates to a Group III nitride semiconductor light-emitting device in which a flat semiconductor layer is formed on a sapphire substrate having an uneven shape and to a method for producing the same.
- the Group III nitride semiconductor light-emitting device In the Group III nitride semiconductor light-emitting device, light may be reflected to the semiconductor layer side at the interface between the semiconductor layer and the atmospheric layer.
- the refractive index of GaN is 2.3 (blue LED), whereas that of air is 1, and there is a large difference.
- a sapphire substrate having an uneven shape on the main surface may be used for the Group III nitride semiconductor light-emitting device. In such a semiconductor light-emitting device, light is scattered by the uneven shape, and the light extraction efficiency is high.
- Japanese Patent Application Laid-Open (kokai) No. 2011-129718 discloses a Group III nitride semiconductor light-emitting device having a substrate provided with protrusions. Light which is totally reflected at the interface between the substrate and an n-type semiconductor layer or an interface between the p-electrode and the atmospheric layer and propagates in the lateral direction, is scattered by the projections, and thereby improving the light extraction efficiency.
- MOCVD Metal Organic Chemical Vapor Deposition
- a semiconductor layer is easy to grow obliquely on the buffer layer on the inclined surface of the uneven shape.
- the semiconductor layer is easy to grown on that inclined surface.
- GaN is easy to grow on a ⁇ 1, 1, ⁇ 2, 0 ⁇ plane.
- the degree of growth of semiconductor on the inclined surface of the substrate is sometimes higher than that on the main surface of the substrate.
- the bottom area is small on the sapphire substrate, the degree of growth of semiconductor on the inclined surface is remarkably high.
- the crystal orientation of the semiconductor layer grown on the inclined surface is different from that of the semiconductor layer grown on the bottom surface.
- the pitch width of the tops of the adjacent mesas is small, the light extraction efficiency is improved.
- the smaller the pitch width the more difficult the surface of the base layer is to be flat.
- an object of the present invention is to provide a Group III nitride semiconductor light-emitting device in which a flat semiconductor layer is grown on a substrate provided with an uneven shape, and a method for producing the same.
- a method for producing a Group III nitride semiconductor light-emitting device comprising:
- R Area ratio of the flat surface to the total area of the sapphire substrate
- the supply amount of the raw material gas containing a Group V element supplied to the uneven shape of the sapphire substrate is suppressed.
- the growth of the semiconductor layer on the low-temperature buffer layer formed on the inclined surface of the sapphire substrate can be suppressed. Therefore, a flat semiconductor layer can be formed on the sapphire substrate having the uneven shape.
- a second aspect of the present invention is drawn to a specific embodiment of the production method for the Group III nitride semiconductor light-emitting device, wherein in formation of the first semiconductor layer, a layer to at least partially fill in the height of the uneven shape of the sapphire substrate is formed as the first semiconductor layer.
- a third aspect of the present invention is drawn to a specific embodiment of the production method for the Group III nitride semiconductor light-emitting device, wherein the first semiconductor layer partially covers the height of the uneven shape of the sapphire substrate, and does not cover the remaining part of the height of the uneven shape.
- a fourth aspect of the present invention is drawn to a specific embodiment of the production method for the Group III nitride semiconductor light-emitting device, wherein the first semiconductor layer covers the entire height of the uneven shape of the sapphire substrate.
- a fifth aspect of the present invention is drawn to a specific embodiment of the production method for the Group III nitride semiconductor light-emitting device, wherein the semiconductor layer formation step includes forming an n-type semiconductor layer on the first semiconductor layer, forming a light-emitting layer on the n-type semiconductor layer, and forming a p-type semiconductor layer on the light-emitting layer.
- a sixth aspect of the present invention is drawn to a specific embodiment of the production method for the Group III nitride semiconductor light-emitting device, wherein in formation of the first semiconductor layer, the growth temperature of the first semiconductor layer is lower within a range of 20° C. to 80° C. than that of the n-type semiconductor layer.
- a seventh aspect of the present invention is drawn to a specific embodiment of the production method for the Group III nitride semiconductor light-emitting device, wherein in formation of the n-type semiconductor layer, the growth temperature of the n-type semiconductor layer is from 1,000° C. to 1,200° C.
- An eight aspect of the present invention is drawn to a specific embodiment of the production method for the Group III nitride semiconductor light-emitting device, wherein the uneven shape of the sapphire substrate has a height of 0.5 ⁇ m to 3.0 ⁇ m.
- a ninth aspect of the present invention is drawn to a specific embodiment of the production method for the Group III nitride semiconductor light-emitting device, wherein an angle between the bottom surface of the uneven shape of the sapphire substrate and the maximum inclined surface of the uneven shape is from 40° to 60°.
- a tenth aspect of the present invention is drawn to a specific embodiment of the production method for the Group III nitride semiconductor light-emitting device, wherein in formation of the first semiconductor layer, the growth speed of the first semiconductor layer is from 200 ⁇ /min to 2,000 ⁇ /min.
- An eleventh aspect of the present invention is drawn to a specific embodiment of the production method for the Group III nitride semiconductor light-emitting device, wherein the uneven shape of the sapphire substrate has a plurality of mesas, the mesas are disposed in a honeycomb structure over the entire surface of the uneven shape.
- a twelfth aspect of the present invention is drawn to a specific embodiment of the production method for the Group III nitride semiconductor light-emitting device, wherein the mesa has at least one selected from a group consisting of a truncated cone shape, a hexagonal truncated pyramid shape, a cone shape, and a hexagonal pyramid shape.
- a thirteenth aspect of the present invention is drawn to a specific embodiment of the production method for the Group III nitride semiconductor light-emitting device, wherein a line connecting the adjacent mesas is in an a-axis direction.
- a fourteenth aspect of the present invention is drawn to a specific embodiment of the production method for the Group III nitride semiconductor light-emitting device, wherein the sapphire substrate has a c-plane main surface.
- a fifteenth aspect of the present invention is drawn to a specific embodiment of the production method for the Group III nitride semiconductor light-emitting device, wherein ammonia is used as the raw material gas containing a Group III element and at least trimethylgallium is used as the raw material gas containing a Group V element.
- a Group III nitride semiconductor light-emitting device comprising a sapphire substrate provided with an uneven shape having at least an inclined surface; a low-temperature buffer layer formed along the uneven shape on the sapphire substrate; a first semiconductor layer formed on the low-temperature buffer layer and at least partially fills in the height of the uneven shape; an n-type semiconductor layer formed on the first semiconductor layer; a light-emitting layer formed on the n-type semiconductor layer; and a p-type semiconductor layer formed on the light-emitting layer; wherein an area ratio R of a flat surface area S on the main surface side to a total area K of the sapphire substrate is 10% or more to less than 50%.
- the first semiconductor layer has an inclined surface growth layer grown on the inclined surface of the uneven shape.
- the inclined surface growth layer has a thickness of 0.05 ⁇ m to 0.5 ⁇ m.
- the Group III nitride semiconductor light-emitting device comprises the sapphire substrate having a finer uneven shape and the first semiconductor layer. Light scatters well by the mesas and the dents of the uneven shape, and the light extraction efficiency is high.
- the growth speed of the semiconductor layer is slow on the inclined surface of the uneven shape of the sapphire substrate. Therefore, the growth of the semiconductor layer on the main surface of the sapphire substrate is not inhibited by the growth of the semiconductor layer on the inclined surface of the uneven shape of the sapphire substrate.
- the growth mode of the semiconductor layers above the first semiconductor layer is stable. Thus, the semiconductor layers above the first semiconductor layer have good crystal quality.
- a seventeenth aspect of the present invention is drawn to a specific embodiment of the Group III nitride semiconductor light-emitting device, wherein an n-electrode is formed in contact with the n-type semiconductor layer, and the n-type semiconductor layer includes an n-type contact layer in contact with the n-electrode.
- An eighteenth aspect of the present invention is drawn to a specific embodiment of the Group III nitride semiconductor light-emitting device, wherein, an n-electrode is formed in contact with the n-type semiconductor layer, and the first semiconductor layer includes an n-type contact layer in contact with the n-electrode.
- the present invention enables provision of a Group III nitride semiconductor light-emitting device in which a flat semiconductor layer is grown on a sapphire substrate having an uneven shape, and a production method therefor.
- FIG. 1 is a sketch showing the case where a raw material gas is sprayed on a flat sapphire substrate having no uneven shape
- FIG. 2 is a sketch showing the case where a raw material gas is sprayed on a sapphire substrate having an uneven shape
- FIG. 3 shows a schematic structure of a semiconductor light-emitting device according to an embodiment
- FIG. 4 shows a sapphire substrate of the semiconductor light-emitting device according to the embodiment
- FIG. 5 is a schematic cross-sectional view around a base layer of the semiconductor light-emitting device according to the embodiment.
- FIG. 6 is a sketch (part 1 ) showing processes for producing the light-emitting device according to the embodiment
- FIG. 7 is a sketch (part 2 ) showing processes for producing the light-emitting device according to the embodiment
- FIG. 8 a sketch (part 3 ) showing processes for producing the light-emitting device according to the embodiment
- FIG. 9 a sketch (part 4 ) showing processes for producing the light-emitting device according to the embodiment.
- FIG. 10 a sketch (part 5 ) showing processes for producing the light-emitting device according to the embodiment
- FIG. 11 is a photomicrograph showing the growth of a semiconductor layer on a sapphire substrate according to an example
- FIG. 12 is a photomicrograph showing the growth of a semiconductor layer on a sapphire substrate according to a comparative example
- FIG. 13 shows a schematic structure (part 1 ) of a semiconductor light-emitting device according to a modification
- FIG. 14 shows a schematic structure (part 2 ) of the semiconductor light-emitting device according to the modification.
- each layer and electrodes forming the below-mentioned light-emitting devices are merely examples, and may differ from those exemplified in the below-described embodiments.
- the thickness of each layer, which is schematically shown in the drawings, does not correspond to its actual value.
- FIG. 3 shows a schematic structure of a light-emitting device 100 according to the present embodiment.
- the light-emitting device 100 is a face-up type semiconductor light-emitting device.
- the light-emitting device 100 comprises a plurality of semiconductor layers formed of Group III nitride semiconductor.
- the light-emitting device 100 comprises a sapphire substrate 110 , a low-temperature buffer layer 120 , a base layer 130 , an n-type semiconductor layer 140 , a light-emitting layer 150 , a p-type semiconductor layer 160 , a transparent electrode 170 , an n-pad electrode N 1 , and a p-pad electrode P 1 .
- the sapphire substrate 110 is a growth substrate for forming semiconductor layers on its main surface through MOCVD.
- An uneven shape 111 is formed on the main surface of the sapphire substrate 110 .
- the uneven shape 111 will be described later.
- the low-temperature buffer layer 120 is formed on the uneven shape 111 of the sapphire substrate 110 .
- the low-temperature buffer layer 120 is formed in an uneven shape along the uneven shape 111 .
- the low-temperature buffer layer 120 is employed so as to form crystallization cores at high density in the sapphire substrate 110 .
- the low-temperature buffer layer 120 is made of a material such as AlN or GaN.
- the low-temperature buffer layer 120 has a thickness of 10 ⁇ to 1,000 ⁇ .
- the base layer 130 is formed on the low-temperature buffer layer 120 .
- the base layer 130 is a first semiconductor layer that partially fills in the height of the uneven shape 111 of the sapphire substrate 110 . Therefore, the base layer 130 covers the bottom surface and a portion of the inclined surface of the uneven shape 111 . The base layer 130 does not cover the remaining portion of the inclined surface and the top of the uneven shape 111 .
- the base layer 130 is a GaN layer.
- the n-type semiconductor layer 140 is formed on the base layer 130 .
- the n-type semiconductor layer 140 comprises an n-type contact layer, an n-type ESD layer, and an n-type superlattice layer, which are sequentially formed on the base layer 130 .
- the surface on the sapphire substrate 110 side of the n-type semiconductor layer 140 has a certain degree of uneven shape. That is, the n-type semiconductor layer 140 fills in the uneven shape to a certain degree on the surface of the base layer 130 .
- the surface opposite to the sapphire substrate 110 side of the n-type semiconductor layer 140 i.e., the surface on the light-emitting layer 150 side is flat.
- the n-type contact layer is in contact with the n-electrode N 1 .
- the light-emitting layer 150 is formed on the n-type semiconductor layer.
- the light-emitting layer 150 emits light through recombination of electrons and holes.
- the light-emitting layer 150 is formed on the n-type semiconductor layer 140 .
- the light-emitting layer comprises a well layer and a barrier layer.
- the p-type semiconductor layer 160 is formed on the light-emitting layer 150 .
- the p-type semiconductor layer 160 comprises a p-type cladding layer and a p-type contact layer which are sequentially deposited on the light-emitting layer 150 . These are merely examples, and other deposit structures may be employed.
- the transparent electrode 170 is formed on the p-type semiconductor layer 160 .
- the transparent electrode 170 is in ohmic contact with the p-type contact layer of the p-type semiconductor layer 160 .
- the transparent electrode 170 is made of ITO.
- transparent conductive oxide such as ICO, IZO, ZnO, TiO 2 , NbTiO 2 , and TaTiO 2 may be used.
- the p-electrode P 1 is a p-pad electrode formed on the transparent electrode 170 .
- the p-electrode P 1 is formed by sequentially forming V film and Al film on the transparent electrode 170 .
- the p-electrode P 1 may be formed by sequentially forming Ti film and Al film or Ti film and Au film.
- the n-electrode N 1 is an n-pad electrode formed on the n-type contact layer of the n-type semiconductor layer 140 .
- the n-electrode N 1 is in ohmic contact with the n-type contact layer.
- the n-electrode N 1 is formed by sequentially forming V film and Al film on the n-type contact layer.
- the n-electrode N 1 may be formed by sequentially forming Ti film and Al film or Ti film and Au film.
- FIG. 4 shows an enlarged cross-sectional view of the sapphire substrate 110 .
- the main surface of the sapphire substrate 110 has the uneven shape 111 .
- the sapphire substrate 110 has a bottom surface 111 a and mesas 112 .
- Each mesa 112 has a truncated cone shape comprising a top surface 112 a and an inclined surface 112 b .
- the mesas 112 are disposed in a honeycomb structure over the entire surface of the uneven shape 111 of the sapphire substrate 110 .
- a height h of the mesa 112 i.e., a distance between the bottom surface 111 a and the top surface 112 a is from 0.5 ⁇ m to 3.0 ⁇ m.
- An angle ⁇ between the inclined surface 112 b and the bottom surface 111 a is from 40° to 60°.
- a distance between the centers of the adjacent mesas 112 i.e., a pitch width W 1 is from 1.0 ⁇ m to 3.0 ⁇ m.
- a width W 2 of the mesa 112 , at a level of the bottom surface 111 a is from 2 ⁇ m to 4 ⁇ m.
- An interval W 3 between the adjacent mesas 112 , at a level of the bottom surface 111 a is from 0.1 ⁇ m to 1 ⁇ m.
- the low-temperature buffer layer 120 formed on the sapphire substrate 110 covers the bottom surface 111 a , the top surface 112 a , and the inclined surface 112 b .
- the base layer 130 grows on the low-temperature buffer layer 120 formed on the bottom surface 111 a , the top surface 112 a , and the inclined surface 112 b .
- a flat semiconductor layer is formed on the low-temperature buffer layer 120 formed on the bottom surface 111 a and the top surface 112 a .
- a semiconductor layer is obliquely grown on the low-temperature buffer layer 120 formed on the inclined surface 112 b .
- the semiconductor layer grown on the inclined surface 112 b is not flat.
- the present embodiment is characterized in that the partial pressures of raw material gases supplied are adjusted according to the area ratio of a flat portion of the sapphire substrate 110 .
- the supply amount of the raw material gases can be adjusted, for example, by using a mass flow controller.
- the gas partial pressure can be easily calculated by the supply amount of the gas.
- PR1 Partial pressure of ammonia gas (raw material gas containing a Group V element)
- the partial pressure ratio is calculated by the measured values of the gas supply amount at the supply valve which supplies the gases to the MOCVD furnace.
- the condition of the equation (1) may be employed when a semiconductor layer is formed on a substrate having no uneven shape. It may also be employed for a substrate having an uneven shape and having a large area ratio (R>0.5) of the sum of the bottom surface and the top surface to the total area of the sapphire substrate.
- R Area ratio of the flat surface to the total area of the sapphire substrate
- PR1 Partial pressure of ammonia gas (raw material gas containing a Group V element)
- the area K is the total surface area of the sapphire substrate 110 , that is, the area K is the same as the main surface area of the sapphire substrate 110 having no uneven shape.
- the area S is the area of the flat surface of the sapphire substrate 110 .
- the flat surface includes the main surface of the sapphire substrate 110 and the surface having an angle of 10° or less to the main surface. That is, the area S is the total area of the main surface, the surface parallel thereto, and the surface slightly inclined therefrom.
- the flat surface area S of the sapphire substrate 110 is the sum of the area of the bottom surface 111 a and the area of the top surface 112 a .
- the area ratio R is the area ratio of the total area of the bottom surface 111 a and the top surface 112 a to the total area K of the sapphire substrate 110 .
- the partial pressure ratio Y of a raw material gas containing a Group V element to a raw material gas containing a Group III element is decreased according to the area ratio of the flat surface (the bottom surface 111 a and the top surface 112 a ) to the total area of the sapphire substrate 110 when forming the base layer 130 on the low-temperature buffer layer 120 .
- the base layer 130 can be formed mainly on the bottom surface 111 a of the sapphire substrate 110 .
- FIG. 5 is a schematic cross-sectional view around the sapphire substrate 110 and the base layer 130 of the semiconductor light-emitting device 100 according to the embodiment. Such cross section can be observed, for example, by a Transmission Electron Microscope (TEM), and in some cases, a Scanning Electron Microscope (SEM).
- TEM Transmission Electron Microscope
- SEM Scanning Electron Microscope
- the base layer 130 comprises flat surface growth layers 131 and 132 , and an inclined surface growth layer 133 .
- the flat surface growth layer 131 is a semiconductor layer grown on a flat surface 121 of the low-temperature buffer layer 120 .
- the flat surface growth layer 132 is a semiconductor layer grown on a top surface 122 of the low-temperature buffer layer 120 .
- the inclined surface growth layer 133 is a semiconductor layer grown on an inclined surface 123 of the low-temperature buffer layer 120 .
- the flat surface growth layer 131 grown on the flat surface 121 and the flat surface growth layer 132 grown on the top surface 122 have the same crystal orientation. Therefore, when an n-type semiconductor layer is formed on these semiconductor layers, the semiconductor layers are easily merged into a flat layer. When there is no top surface 122 , needless to say, a semiconductor layer does not grow on the top surface.
- a thickness t 1 of the inclined surface growth layer 133 is sufficiently thin.
- the thickness t 1 of the inclined surface growth layer 133 is the thickness of the thickest portion of the inclined surface growth layer 133 .
- the thickness t 1 is measured in a direction perpendicular to the inclined surface 112 b , as shown in FIG. 5 .
- the thickness t 1 of the inclined surface growth layer 133 is from 0.05 ⁇ m to 0.5 ⁇ m.
- the growth of the flat surface growth layer 131 is dominant, and the thickness of the inclined surface growth layer 133 is suppressed. This is because the raw material gases are supplied so as to satisfy the condition of the aforementioned equation (2).
- the method for producing the light-emitting device 100 will be described.
- the aforementioned respective semiconductor layers are formed through epitaxial crystal growth by metal-organic chemical vapor deposition (MOCVD).
- the method for producing the light-emitting device 100 comprises the steps of forming an n-type semiconductor layer; forming a light-emitting layer on the n-type semiconductor layer; and forming a p-type semiconductor layer on the light-emitting layer.
- a c-plane of the sapphire substrate is processed to form the uneven shape 111 .
- a photo-resist is formed as a mask.
- dry etching is performed to prepare the sapphire substrate 110 having the uneven shape 111 on the main surface thereof.
- a sapphire substrate 110 on which the uneven shape 111 has been formed may be purchased.
- the sapphire substrate 110 is put inside the MOCVD furnace. Thereafter, a semiconductor layer is formed by MOCVD. After cleaning with H 2 , the low-temperature buffer layer 120 is formed on the uneven shape 111 of the sapphire substrate 110 . Thus, as shown in FIG. 6 , the low-temperature buffer layer 120 is formed on the bottom surface 111 a , the top surface 112 a , and the inclined surface 112 b of the sapphire substrate 110 . The low-temperature buffer layer 120 is thin enough not to fill in the uneven shape 111 of the sapphire substrate 110 .
- the carrier gas employed in MOCVD is hydrogen (H 2 ), nitrogen (N 2 ), or a gas mixture of hydrogen and nitrogen (H 2 +N 2 ).
- Ammonia gas (NH 3 ) is employed as a nitrogen source.
- Trimethylgallium (Ga(CH 3 ) 3 : hereinafter referred to as “TMG”) is employed as a Ga source.
- Trimethylindium (In(CH 3 ) 3 : hereinafter referred to as “TMI”) is employed as an In source.
- Trimethylaluminum (Al(CH 3 ) 3 : hereinafter referred to as “TMA”) is employed as an Al source.
- Silane (SiH 4 ) is employed as an n-type dopant gas.
- Cyclopentadienylmagnesium (Mg(C 5 H 5 ) 2 ) is employed as a p-type dopant gas.
- the base layer 130 is formed on the low-temperature buffer layer 120 .
- Gases are supplied so that the partial pressure ratio Y of a raw material gas containing a Group V element to a raw material gas containing a Group III element satisfies the aforementioned equation (2).
- the growth temperature in the base layer formation step is lower by any temperature within a range of 20° C. to 80° C. than that in the n-type semiconductor layer formation step.
- the growth rate of the base layer is from 200 ⁇ /min to 2,000 ⁇ /min.
- the uneven shape 111 of the sapphire substrate 110 is partially filled in, thereby forming the base layer 130 having the surface 131 a.
- the n-type semiconductor layer 140 is formed on the flat base layer 130 , and then the n-type contact layer is formed.
- the substrate temperature in this step is from 1,000° C. to 1,200° C.
- the Si concentration is 1 ⁇ 10 18 /cm 3 or more.
- the growth temperature of the n-type semiconductor layer 140 is higher than that of the base layer 130 .
- the growth rate in a lateral direction is high in this step. Therefore, the remaining part of the uneven shape that was partially filled in by the base layer 130 is easily filled in by the n-type semiconductor layer 140 . In this way, the uneven shape partially remaining in the base layer 130 is filled in. Thereby, the top surface of the n-type semiconductor layer 140 is flat.
- An n-type ESD layer or an n-side superlattice layer may be formed on the n-type contact layer. Even in the semiconductor layer formation step after this step, the equation (2) is employed.
- the light-emitting layer 150 is formed on the n-type semiconductor layer 140 .
- the substrate temperature is adjusted to 700° C. to 950° C.
- the p-type semiconductor layer 160 is formed on the light-emitting layer 150 .
- a p-side superlattice layer is formed on the light-emitting layer 150 , and the p-type contact layer is formed thereon.
- the substrate temperature at the formation of the p-type contact layer is adjusted to 900° C. to 1,050° C.
- the above-mentioned semiconductor layers are deposited on the sapphire substrate 110 as shown in FIG. 8 .
- a recess 141 is formed for forming the n-electrode N 1 .
- the transparent electrode 170 is formed on the p-type contact layer of the p-type semiconductor layer 160 .
- the p-electrode P 1 is formed on the transparent electrode 170 .
- the semiconductor layer deposited structure is partially removed through laser radiation or etching from the p-type contact layer, to thereby expose the n-type contact layer.
- the n-electrode N 1 is formed on the exposed area of the n-type contact layer. Formation of the p-electrode P 1 and formation of the n-electrode N 1 may be carried out in any order. When the electrode material is the same, they may be carried out at the same time.
- insulating film formation for covering the device, thermal treatment, and other steps may be performed. Through carrying out the steps, production of the light-emitting device 100 shown in FIG. 3 is complete.
- the process from the base layer formation step to the p-type semiconductor layer formation step is a semiconductor layer formation step in which the semiconductor layers made of Group III nitride semiconductor are formed on the low-temperature buffer layer 120 .
- the area ratio (R) of the flat surface to the total area of the sapphire substrate is 14%.
- the material of the low-temperature buffer layer was AlN.
- the thickness was 100 ⁇ .
- the partial pressure Y was 400 in the example and 1,200 in the comparative example.
- FIG. 11 is a photomicrograph showing the example according to the present embodiment.
- the growth of the semiconductor layer is suppressed on the side surfaces of the mesas or the dents, that is, the low-temperature buffer layer 120 formed on the inclined surface 112 b .
- the growth of the semiconductor layer is promoted on the low-temperature buffer layer 120 formed on the bottom surface 111 a .
- the growth of the semiconductor layer on the flat surface is dominant, and the growth of the semiconductor layer is suppressed on the side surfaces of the mesas or the dents.
- a boundary surface between the semiconductor layer grown on the bottom surface 111 a and the semiconductor layer grown on the inclined surface 112 b can be observed, for example, in a cross-sectional photo taken by a Transmission Electron Microscope (TEM).
- TEM Transmission Electron Microscope
- a semiconductor layer is not much grown on the low-temperature buffer layer 120 formed on the inclined surface 112 b .
- FIG. 12 is a photomicrograph showing the comparative example.
- a semiconductor layer grows well on the inclined surface 112 b side of the mesa 112 , that is, the low-temperature buffer layer 120 formed on the inclined surface 112 b . Since the growth of the semiconductor layer on the side surface of the mesa 112 is dominant, the semiconductor layer grown thereon, that is, the layer above the base layer 130 , that is, the semiconductor layer on the side opposite to the sapphire substrate 110 is difficult to have a flat surface. A flat base layer 130 is not achieved, and it is difficult to form a semiconductor layer superior in crystallinity on the base layer.
- the base layer 130 may be formed of n-type GaN instead of GaN. Alternatively, it may be formed of AlGaN or InGaN instead of GaN. It may be formed of Al X In Y Ga (1-X-Y) N (0 ⁇ X, 0 ⁇ Y, X+Y ⁇ 1). However, in that case, the Al composition ratio is 0.2 or less, and the In composition ratio is 0.2 or less.
- Trimethylindium or trimethylaluminum is supplied as a raw material gas.
- the partial pressure of the raw material gas containing a Group III element in the equation (1) or (2) is the total partial pressures of these TMI, TMA, and TMG gases.
- the present embodiment was applied to the face-up type semiconductor light-emitting device. Needless to say, it may be applied to other types of semiconductor light-emitting devices, for example, a flip-chip type semiconductor light-emitting device 200 having a light extraction surface on the substrate as shown in FIG. 13 . Therefore, a light extraction surface 201 is on a sapphire substrate 210 . Other structures are the same as in FIG. 3 .
- the mesa 112 has a truncated cone shape. It may have a cone shape, a hexagonal pyramid shape, or a hexagonal truncated pyramid shape. Needless to say, it may have other pyramid shape or other truncated pyramid shape. Even in that case, an angle between the maximum inclined surface and the bottom surface is from 40° to 60°.
- a line connecting the tops of the mesas 112 is preferably in an a-axis direction of the base layer 130 .
- the mesas are suitably grown on the bottom surface 111 a.
- the base layer formed on the low-temperature buffer layer 120 may fill in the entire height of the uneven shape 111 .
- a filling-in layer 330 is formed on the low-temperature buffer layer 120 .
- the filling-in layer 330 may be an n-type GaN layer.
- the filling-in layer 330 is a first n-type semiconductor layer
- an n-type semiconductor layer 340 is a second n-type semiconductor layer.
- the base layer 130 and the filling-in layer 330 are the first semiconductor layer that at least partially fills in the height of the uneven shape 111 of the sapphire substrate 110 .
- the filling-in layer 330 is a layer that plays a role to suppress the growth of the semiconductor layer on the inclined surface 123 .
- Other structures are the same as in FIG. 3 .
- the area ratio R was 10% or more to less than 50%.
- the smaller the area ratio R the more the supply gas easily accumulates in the region R 1 . Therefore, the smaller the area ratio R, the higher the effect of the present embodiment.
- the effect produced by changing the partial pressure ratio of the gases supplied is large, that is, when the area ratio R satisfies the following equation, a higher effect is obtained.
- R Area ratio of the flat surface to the total area of the sapphire substrate
- the sapphire substrate 110 was used, in which the mesas 112 are disposed in a honeycomb structure in the uneven shape 111 .
- a sapphire substrate having dents disposed in a honeycomb structure in the uneven shape may be used.
- the uneven shape is formed on the sapphire substrate having a c-plane main surface.
- a sapphire substrate other than that having a c-plane main surface may be used, e.g. a sapphire substrate having an a-plane main surface.
- the partial pressures of ammonia and trimethylgallium supplied to the uneven shape 111 of the sapphire substrate 110 were adjusted. That is, the supply amount of ammonia to the uneven shape 111 was decreased when the area of the bottom surface of the sapphire substrate 110 or the surface parallel thereto is sufficiently small. This suppresses the growth of the semiconductor layer on the inclined surface of the sapphire substrate 110 , fills in the uneven shape 111 of the sapphire substrate 110 , thereby forming a flat base layer. Thus, a light-emitting device 100 having superior crystal quality and high light extraction efficiency is achieved.
- the deposit structure of the deposited body is not necessarily limited to those illustrated.
- the deposit structure, etc. may be determined.
- the layer formation method is not limited to metal-organic chemical vapor deposition (MOCVD). Any other methods, e.g. hydride vapor phase epitaxy may be employed, so long as the semiconductor crystal growth is performed by use of a carrier gas.
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Abstract
Description
1000≦Y/(2×R)≦1200
R=S/K
0.1≦R<0.5
1000≦Y≦1200 (1)
Y=PR1/PR2
1000≦Y/(2×R)≦1200 (2)
Y=PR1/PR2
0.1≦R<0.5
R=S/K
500≦Y≦600
The partial pressure ratio Y of the ammonia gas to the trimethylgallium is about half of the equation (1) in the usual condition, that is, the supply amount of the ammonia gas is relatively small.
4. Base Layer
4-1. Flatness of Base Layer
7-3. Flip-Chip Type
0.1≦R≦0.3
Claims (17)
1000≦Y/(2×R)≦1200
R=S/K
0.1≦R<0.3
1000≦Y/(2×R)≦1200
R=S/K
0.1≦R<0.5
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JP6436694B2 (en) * | 2014-09-17 | 2018-12-12 | 住友化学株式会社 | Manufacturing method of nitride semiconductor template |
TWI569464B (en) * | 2015-10-22 | 2017-02-01 | 隆達電子股份有限公司 | Compound semiconductor thin film structure |
EP3407394A4 (en) * | 2016-01-22 | 2019-06-12 | Oji Holdings Corporation | Semiconductor light-emitting element substrate, and method for manufacturing semiconductor light-emitting element substrate |
US10074721B2 (en) * | 2016-09-22 | 2018-09-11 | Infineon Technologies Ag | Method of fabricating a semiconductor wafer that includes producing a planarised surface having both a mesa surface and an insulating layer surface |
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